PART 1 - GENERAL 1.1 DESCRIPTION SECTION 23 22 23 STEAM CONDENSATE PUMPS SPEC WRITER NOTES: 1. Delete between // ---- // if not applicable to project. Also delete any other item or paragraph not applicable in the section and renumber the paragraph. A. Steam condensate pumps for Heating, Ventilating and Air Conditioning. 1.2 RELATED WORK A. Section 01 00 00, GENERAL REQUIREMENTS. B. Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, and SAMPLES. //C. Section 13 05 41, SEISMIC RESTRAINT REQUIREMENTS FOR NON-STRUCTURAL COMPONENTS.// D. Section 23 05 11, COMMON WORK RESULTS FOR HVAC and STEAM GENERATION. E. Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC and STEAM GENERATION EQUIPMENT. F. Section 23 05 41, NOISE and VIBRATION CONTROL FOR HVAC PIPING and EQUIPMENT. G. Section 23 22 13, STEAM AND CONDENSATE HEATING PIPING. 1.3 QUALITY ASSURANCE A. Refer to Paragraph, QUALITY ASSURANCE in Section 23 05 11, COMMON WORK RESULTS FOR HVAC and STEAM GENERATION. B. Design Criteria: 1. Pumps design and manufacturer shall conform to Hydraulic Institute Standards. 2. Pump sizes, capacities, pressures, operating characteristics and efficiency shall be as scheduled. 3. Select pumps so that required net positive suction head (NPSHR) does not exceed the net positive head available (NPSHA). 4. Pump Driver: Furnish with pump. Size shall be non-overloading at any point on the head-capacity curve including one pump operation in a parallel or series pumping installation. 5. Provide all pumps with motors, impellers, drive assemblies, bearings, coupling guard and other accessories specified. Statically and dynamically balance all rotating parts. 23 22 23-1
6. Furnish each pump and motor with a nameplate giving the manufacturers name, serial number of pump, capacity in GPM and head in feet at design condition, horsepower, voltage, frequency, speed and full load current and motor efficiency. 7. Test all pumps before shipment. The manufacturer shall certify all pump ratings. 8. After completion of balancing, provide replacement of impellers or trim impellers to provide specified flow at actual pumping head, as installed. 9. Furnish one spare seal and casing gasket for each pump to the // Resident Engineer// Project Manager //. C. Allowable Vibration Tolerance for Pump Units: Section 23 05 41, NOISE and VIBRATION CONTROL FOR HVAC PIPING AND EQUIPMENT. 1.4 SUBMITTALS A. Submit in accordance with Section 01 33 23, SHOP DRAWINGS, PRODUCT DATA, and SAMPLES. B. Manufacturer's Literature and Data: 1. Pumps and accessories. 2. Motors and drives. C. Manufacturer's installation, maintenance and operating instructions, in accordance with Section 23 05 11, COMMON WORK RESULTS FOR HVAC and STEAM GENERATION. D. Characteristic Curves: Head-capacity, efficiency-capacity, brake horsepower-capacity, and NPSHR-capacity for each pump. 1.5 APPLICABLE PUBLICATIONS A. The publications listed below form a part of this specification to the extent referenced. The publications are referenced in the text by the basic designation only: B. American Iron and Steel Institute (AISI): AISI 1045...Cold Drawn Carbon Steel Bar, Type 1045 AISI 416...Type 416 Stainless Steel C. American National Standards Institute (ANSI): ANSI B15.1-00(R2008)...Safety Standard for Mechanical Power Transmission Apparatus ANSI B16.1-05...Cast Iron Pipe Flanges and Flanged Fittings, Class 25, 125, 250 and 800 D. American Society for Testing and Materials (ASTM): A48-03(2008)...Standard Specification for Gray Iron Castings 23 22 23-2
B62-09...Standard Specification for Composition Bronze or Ounce Metal Castings E. Maintenance and Operating Manuals in accordance with Section 01 00 00, GENERAL REQUIREMENTS. 1.6 DEFINITIONS A. Capacity: Liters per second (L/s) (Gallons per minute (GPM)) of the fluid pumped. B. Head: Total dynamic head in kpa (feet) of the fluid pumped. PART 2 - PRODUCTS 2.1 CONDENSATE PUMP, PAD-MOUNTED A. General: Factory assembled unit consisting of vented receiver tank, motor-driven pumps, interconnecting piping and wiring, motor controls (including starters, if necessary) and accessories, designed to receive, store, and pump steam condensate. B. Receiver Tank: Cast iron with threaded openings for connection of piping and accessories and facilities for mounting float switches. Receivers for simplex pumps shall include all facilities for future mounting of additional pump and controls. C. Furnish seals for condensate pump with a minimum temperature rating of 121 degrees C (250 degrees F). D. Centrifugal Pumps: Bronze fitted with mechanical shaft seals. 1. Designed to allow removal of rotating elements without disturbing connecting piping or pump casing mounting. 2. Shafts: Stainless steel, AISI Type 416 or alloy steel with bronze shaft sleeves. 3. Bearings: Regreaseable ball or roller type. 4. Casing wearing rings: Bronze. E. Motors: Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC and STEAM GENERATION EQUIPMENT. F. Pump Operation: 1. Float Switches: NEMA 1, mounted on receiver tank, to start and stop pumps in response to changes in the water level in the receiver and adjustable to permit the controlled water levels to be changed. Floats and connecting rods shall be copper, bronze or stainless steel. 2. Alternator: Provide for duplex units to automatically start the second pump when the first pump fails in keeping the receiver water level from rising and to alternate the order of starting the pumps. 23 22 23-3
For units 0.25 kw (1/3 horsepower) and smaller, the alternator may be the mechanical type for use in lieu of float switches. G. Control Cabinet for 3 Phase (0.37 kw (1/2 hp) and larger) Units: NEMA 1, UL approved, factory wired, enclosing all controls, with indicating lights, manual switches and resets mounted on the outside of the panel. Attach cabinet to the pump set with rigid steel framework, unless remote mounting is noted on the pump schedule. 1. Motor starters: Magnetic contact types with circuit breakers or combination fusible disconnect switches. Provide low voltage control circuits (120 volt maximum) and "hand-off-automatic" (H-O-A) switches for each pump. 2. Indicating lights for each pump: Green to show that power is on, red to show that the pump is running. H. Electric Wiring: Suitable for 93 degrees C (200 degrees F) service; enclosed in liquid-tight flexible metal conduit where located outside of control cabinet. I. Receiver Accessories: 1. Thermometer: 34-216 degrees C (100-420 degrees F), mounted below minimum water level. 2. Water level gage glass: Brass with gage cocks which automatically stop the flow of water when the glass is broken. Provide drain on the lower gage cock and protection rods for the glass. 2.2 CONDENSATE PUMP, SUMP TYPE A. General: Factory assembled unit consisting of motor-driven pump(s) mounted on a horizontal cover plate bolted to a vented sump-type receiver, interconnecting wiring and piping, motor controls and accessories, designed to receive, store, and pump steam condensate. B. Receiver Tank: Vertical, cylindrical, cast iron sides and bottom, designed for service underground or below the floor. Inlet connection shall be located nine inches below the cover plate. Provide floor mounting gasket. C. Receiver Cover Plate: Heavy gage steel designed to support weight of pumps, motors, and accessories and support foot traffic with no deflection. Provide for mounting of pumps, motor and accessories by bolting to the cover. Provide threaded openings for piping connections and a bolted inspection plate for viewing interior of receiver. All bolted connections to cover plate, and between cover plate and receiver, shall be gasketed so that no vapor will escape into the room. 23 22 23-4
D. Furnish seals for condensate pump with a minimum temperature rating of 121 degrees C (250 degrees F). E. Pumps: Centrifugal type, vertical extended shaft, bronze fitted, flexible-coupled, designed for submerged operation. 1. Shaft: Stainless steel, AISI Type 416. 2. Shaft bearings: Bronze, water lubricated. 3. Shaft seal at cover plate: Packed type with bronze packing gland. 4. Thrust bearings: Regreaseable ball type located above the cover plate. 5. Discharge pipes: Terminate above the cover plate. 6. Pump-motor mounting: Bolted to brackets bolted to the cover plate. Removal of one pump shall not affect operation of the second pump. F. Motors: Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC and STEAM GENERATION EQUIPMENT. G. Pump Operation: 1. Float Switches: NEMA 1, mounted on receiver tank, to start and stop pumps in response to changes in the water level in the receiver, and adjustable to permit the controlled water levels to be changed. Floats and connecting rods shall be copper, bronze or stainless steel. 2. Alternator: Provide for duplex units to automatically start the second pump when the first pump fails in keeping the receiver water level from rising and to alternate the order of starting the pumps. For units 0.25 kw (1/3 horsepower) and smaller, the alternator may be the mechanical type for use in lieu of float switches. H. Electric Wiring: Suitable for 93 degrees C (200 degrees F) service; enclosed in liquid-tight flexible metal conduit where located outside of control cabinet. DESIGNER NOTE: Vacuum return systems are mostly not used for the VA Facilities. Use this section only where renovation or replacement of the pumps is required in the existing facilities. 2.3 VACUUM PUMP, HEATING A. General: Factory assembled unit consisting of water storage and air separating facilities, duplex water pumps, duplex air pumps, motors, controls and accessories, designed to receive, store, and pump the steam condensate from a vacuum return system. The unit shall also produce the required vacuum. 23 22 23-5
B. Receiver Tank: Cast iron or galvanized steel and shall include water storage and air separation chambers. C. Water and Air Pumps: Centrifugal type, bronze fitted, with mechanical shaft seals. 1. Performance: Rating based on condensate at 71 degrees c (160 degrees F) and 20 kpa (5-1/2 inches of mercury vacuum). Perform test in accordance with factory instructions. 2. Design pump to allow removal of rotating elements without disturbing connecting piping or pump casing mounting. 3. Shafts: Stainless steel. 4. Bearings: Grease-lubricated ball or roller type. 5. Casing Wear Rings: Bronze. D. Motors: Refer to Section 23 05 12, GENERAL MOTOR REQUIREMENTS FOR HVAC and STEAM GENERATION EQUIPMENT. E. Air and Water Pump Operation: 1. Adjustable float switches: Mounted on receiver tank, to start and stop water pumps in response to changes in the water level in the receiver. Floats and connecting rods shall be copper, stainless steel, or bronze. 2. Adjustable vacuum switches: Mounted on receiver tank, to start and stop air pumps in response to vacuum requirements of the heating system. 3. Alternators of water pumps and for air pumps: To alternate the sequence of starting the pumps and to automatically start the second air or water pump when the first pump fails to meet the air or water demand. F. Control Cabinet for 3 Phase (0.37 kw (1/2 Hp) and Larger) Units: NEMA 1, UL approved, factory wired, enclosing all controls, with indicating lights, manual switches and resets mounted on the outside of the panel. Attach cabinet to the pump set with rigid steel framework, unless remote mounting is noted on the pump schedule. 1. Motor starters: Magnetic contactor types with circuit breakers or combination fusible disconnect switches. Provide low voltage control circuits (120 volt maximum) and "hand-off-automatic" (H-O-A) switches for each pump. 2. Indicating lights for each pump: Red to show that the pump is running, green to show pump is off. 23 22 23-6
G. Electric Wiring: Suitable for 93 degrees C (200 degrees F) service; enclosed in liquid tight flexible metal conduit where located outside of control cabinet. H. Accessories Required: 1. Thermometer: Mounted on receiver below minimum water level. 2. Water level gage: Mounted on each compartment of receiver. Provide gage cocks which automatically stop the flow of water when the glass is broken. Provide gage glass protection rods and a drain on the lower gage cock. 3. A compound gage. Refer to Section 23 22 13, STEAM AND CONDENSATE HEATING PIPING. 4. Temperature limit switch: To automatically admit cooling water to the air separation chamber when air separation water temperature exceeds the manufacturer's recommended limit. 5. Automatic water make-up control to the air separation changes: Float switch and solenoid valve. Provide manual by-pass valve. 6. Muffler: When required to prevent the air vent sound from exceeding 90 db on the A scale at a distance of 2 m (6 feet) from the unit. 7. Vacuum breaker: Minimum adjustment range 20 to 50 kpa (5 to 15 inches of mercury), to protect the pump unit from excessive vacuum. SPEC WRITER NOTE: Pressure powered condensate pumps shall be considered if pressure greater than 483 kpa (70 psig) is available. 2.4 PRESSURE POWERED CONDENSATE PUMP A. Pressure-Powered Pump Packages: 1. Pump packages shall be furnished and installed as a packaged assembly of the types, sizes, capacities, and characteristics as shown on the drawings. Pump package shall be rated for 185 degrees C (365 degrees F), maximum condensate temperatures. 2. Pump package(s) shall come completely piped and mounted on a steel skid including (1) receiver/reservoir, two positive displacement pressure-powered pumps as scheduled, interconnecting piping and valves, and all accessories as hereafter specified below: a. The receiver shall be of a steel elevated design, warranted for 1 year against defects in material and workmanship. Receiver shall be 150 PSIG ASME labeled and coded. Receiver shall be sized for the required condensate storage volume and flash steam capacity. Receiver shall be horizontally mounted and have openings of the 23 22 23-7
appropriate size and number including: (2) inlets, (1) vent opening, (1) NPT drain with pipe plug, (1) NPT anode opening with anode, and gauge glass openings with gauge glass set consisting of (2) brass isolation valves and guard rods, and red-line tubular glass. Replaceable magnesium anode, which retards the corrosive action of most waters and adds to the service life of the tanks, shall be furnished with each receiver for corrosion protection. b. Pressure-powered pumps shall be non-electric as shown on the drawings. Units shall be constructed of 1034 kpa (150 psig) ASME labeled and coded fabricated steel body, shall be float operated, and contain a condensate inlet baffle. Each unit shall have (1) inlet check valve, (1) outlet check valve, and gauge glass set with isolation valves. c. The float operating mechanism shall have all moving components constructed of stainless steel and be of a snap acting design with no external seals or packing. The float mechanism shall contain a reinforced stainless steel float, (2) 300 series stainless steel open coil design springs, and spring calibration pins. d. Pressure-powered pumps shall be of a non-cavitating design capable of operation on systems up to the maximum working pressure of the tank rating using steam, compressed air, or other compatible inert gas as the supply (motive) pressure. Units shall be capable of operating at temperatures up to 365 F when pumping from a closed system using a compatible motive gas. Balance and fine tune motive pressure to be 138 kpa (20 psig) higher than the static backpressure. e. Package shall include interconnecting piping between receiver/reservoir and the positive displacement pressure-powered pump(s). Interconnecting suction (fill) line shall be provided to each unit and each suction (fill) line shall include a gate valve for isolation. f. Manufacturer shall provide the following for field installation on each pressure-powered pump: 1) Cycle counter 2) Removable insulation jacket 3) Pressure gauge 23 22 23-8
4) Drain piping g. Provide the following components for each pump: 1) Motive pressure reducing valve 2) Safety relief valve(s) 3) Motive pressure inlet strainer 4) Pressure gauge with pigtail, as required 5) Motive pressure drip trap(s) 6) Motive pressure line check valve(s) 3. The package shall be factory tested as a complete unit using steam as the motive pressure. The pump manufacturer shall furnish appropriate assembly and parts drawings, and installation and operation manuals. The package shall be shipped completely assembled, or with connection match marks if package must be shipped as sub-assemblies. B. Removable Insulation Jacket: 1. The insulation jacket should be of sewn construction with Velcro fasteners and have openings for inlet, outlet, drain, and gauge glass. 2. Materials: a. Liner and jacket shall be silicone impregnated heavy duty glass fiber rated for a maximum temperature of 260 degrees C (500 degrees F). b. Insulation shall be 25 mm (1 inch) minimum thickness, Type E needled glass fiber mat rated for a maximum temperature of 650 degrees C (1200 F). c. Jacket shall be sewn with Nomex thread with a UV inhibitor. PART 3 EXECUTION 3.1 INSTALLATION A. Follow manufacturer's written instructions for pump mounting and start-up. Access/Service space around pumps shall not be less than minimum space recommended by pumps manufacturer. B. Permanently support in-line pumps by the connecting piping only, not from the casing or the motor eye bolt. C. Sequence of installation for base-mounted pumps: 1. Level and shim the unit base and grout to the concrete pad. 2. Shim the driver and realign the pump and driver. Correct axial, angular or parallel misalignment of the shafts. 3. Connect properly aligned and independently supported piping. 23 22 23-9
4. Recheck alignment. D. Pad-mounted Condensate Pump // or Vacuum Pump //: Level, shim, bolt, and grout the unit base onto the concrete pad. E. Sump Type Condensate Pump: Apply two coats of asphalt or bituminous compound on the exterior of the receiver tank, and mount level and flush in the floor with waterproofing gaskets and grouting to prevent ground water from entering the building from around the receiver. F. Coordinate location of thermometer and pressure gauges as per Section 23 22 13, STEAM and CONDENSATE HEATING PIPING. 3.2 START-UP A. Verify that the piping system has been flushed, cleaned and filled. B. Lubricate pumps before start-up. C. Prime the pump, vent all air from the casing and verify that the rotation is correct. To avoid damage to mechanical seals, never start or run the pump in dry condition. D. Verify that correct size heaters-motor over-load devices are installed for each pump controller unit. E. Field modifications to the bearings and or impeller (including trimming) are not permitted. If the pump does not meet the specified vibration tolerance send the pump back to the manufacturer for a replacement pump. All modifications to the pump shall be performed at the factory. - - - E N D - - - 23 22 23-10